Innovations in Briquette Press Machines: Integration of a Modified AISI 316L Screw Conveyor and Pneumatic Cutting Automation

Introduction

Biomass-based alternative energy sources, such as charcoal briquettes, are a crucial solution for reducing dependence on fossil fuels. However, in the small and medium-sized enterprise (SME) sector, production efficiency is often hindered by the durability of machine components and inconsistent manual cutting processes. This project aims to design a more economical, durable, and fully automated briquette-making machine to increase production capacity.

Design Methodology

The development process for this machine employs the Shigley Method, which encompasses needs identification, problem formulation, concept synthesis, analysis and optimization, and final evaluation. Using a design evaluation matrix (Weighted Objectives), a design was selected that prioritizes material durability, dimensional efficiency, and energy savings.

Technical Specifications and Mechanical Analysis

The machine is designed with physical dimensions of 750 mm x 500 mm x 1100 mm and uses an electric motor as the primary drive. The following is an analysis of its main components:

1. Power Transmission System

Uses a 1.5 HP (1100 Watt) electric motor with a maximum rotational speed of 1400 RPM. Power is transmitted through a 1:10 reduction gearbox and a pulley system with an A-type V-belt to drive the screw conveyor shaft at an operational speed of 160 RPM.

1. Screw Conveyor Modification

One of the key innovations is the use of AISI 316L (Stainless Steel) material for the screw components. This material was selected for its excellent corrosion resistance and superior mechanical properties compared to standard steel, to minimize component damage that typically occurs after 250 hours of use. The screw has a diameter of 90 mm with a pitch of 35 mm to ensure optimal compaction of the briquette mixture before entering the molding channel.

Automation of Cutting Systems

To reduce manual labor, this machine integrates an electronically controlled pneumatic system:

• Microcontroller (Arduino Uno): Acts as the data processing unit for the HC-SR04 ultrasonic sensor.
• Cutting Mechanism: The sensor detects the length of the briquette exiting the extruder. Once the specified length is reached, the Arduino sends a signal to the relay to activate the 5/2-way solenoid valve.
• Pneumatic Actuator: Compressed air from an 8-bar compressor drives a double-acting cylinder equipped with a cutting blade to produce precision-sized 4 cm x 4 cm x 4 cm cubic briquettes.

Test Results and Conclusions

Based on functional testing, the machine successfully operated at an actual production capacity of 15 kg/hour. The use of a pneumatic system and ultrasonic sensors has proven effective in automatically producing uniform briquette cuts, thereby improving time efficiency and reducing operational costs for SMEs. The integration of traditional mechanical engineering principles with modern control systems demonstrates that modifications to critical components and the implementation of automation can significantly extend the service life and enhance the productivity of industrial equipment.